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Saturday, July 9, 2011

How to remove cylinder head on 1996 Saab 900 turbo?

Here is the proceedure for removing the cylinder head:

NOTE: Step numbers below refer to numbers used in the illustrations.1. Drape protective covers over the fenders to protect the paintwork, drain the coolant and disconnect the negative battery cable.2. Unplug the mass air flow sensor connector and disconnect the inlet hose.• Remove the air cleaner.3. This step is not applicable to this model.4. Lift off the cover or the resonator.5. This step is not applicable to this model.6. Relieve the belt tensioner of strain, using a ratchet handle extension, and insert a 6 mm drill in the hole as shown.• Remove the belt.NOTE: Exercise the utmost care to ensure that the belt tensioner does not break at its end position.7. Undo and move aside the servo pump.8. This step is not applicable to this model.9. This step is not applicable to this model..10. Disconnect the coolant hoses from the cylinder head.11. This step is not applicable to this model.12. Remove the bracket for the dipstick tube and remove the tube.• Disconnect the crankcase breather and vacuum hoses from the camshaft cover.13. Remove the lifting eyes at the intake manifold and move the bracket for the electrical connections to one side.14. Disconnect the throttle body preheating hose and the bolts securing the water pipe to the thermostat housing cover.15. Unplug the temperature sensor connector (adjacent to the intake manifold).16. Undo the bolts securing the intake manifold steady bar and remove the intake manifold.17. Remove the cover plate, ignition cables and distributor cap.• Remove the spark plugs.18. Remove the camshaft cover, line up the 0°mark on the flywheel with the timing mark and check that the timing marks on the camshafts are also in line.19. Remove the chain tensioner.• After removing the plug a 27 mm socket can be used.20. Remove the camshaft sprockets and position the chain so that it will not obstruct removal of the cylinder head.21. Remove the cylinder head.• Start with the timing cover bolts and continue in reverse assembly order.• Use protective collar 75 19 531 to collect the bolts.22. Wipe up any oil that has run out.• Make sure that the timing chain does not obstruct its removal and then lift off the cylinder head.

These pictures are to be referenced with the above steps for removal:

Here is the proceedure for reinstalling the cylinder head:

1. Thoroughly clean all the flange surfaces for the gaskets, rotate the crankshaft through 45°and install the cylinder head. Make sure that it is correctly seated in the locating sockets and that the chain is not trapped.2. Install the 10 torx bolts and using the sequence shown, tighten them in three stages: Stage I: 40 Nm ( 30 ft. lbs. ). Stage II: 60 Nm ( 44 ft. lbs. ). Stage III: tighten a further quarter-turn (90°).3. Install the two bolts securing the timing cover to the cylinder head and tighten to: XXXXX XXXXX (16 ft. lbs.).4. Check that the camshafts are in line with their timing marks and that the 0°mark on the crankshaft is in line with the timing mark.5. Install the camshaft sprockets and chain.• Start with the camshaft on the inlet side.• Do not tighten the bolts yet.6. Prepare the chain tensioner for installing by pressing down the catch and pushing in the chain tensioner.7. Install the chain tensioner, using a 27 mm socket, then tighten to: XXXXX XXXXX (47 ft. lbs.).8. Install the plug for the chain tensioner with push rod and spring, then tighten to: XXXXX XXXXX (16 ft. lbs.).9. Check that the chain is correctly seated in the guides.• Rotate the crankshaft two complete turns and check that the timing marks on the flywheel and camshafts are still in alignment.10. Tighten the camshaft sprocket bolts to: XXXXX XXXXX (47 ft. lbs.).11. Clean the flanges of the camshaft cover, using a suitable solvent.12. Apply soap to the open end of the camshaft cover and install the cover, starting at the open end. Then tighten the bolt located furthest to the front at the timing end. Then continue all the way round, on both the inside and outside, tighten to: XXXXX XXXXX (11 ft. lbs.).13. Install the spark plugs and tighten to: XXXXX XXXXX (20.7 ft. lbs.).14. Install the ignition discharge module or the cover plate, tighten to: XXXXX XXXXX (8 ft. lbs.).• Install the ignition cables and distributor cap.15. Align the intake manifold gasket with the aid of guide pins tool No. 83 94 736, or equivalent, and install the intake manifold, then tighten to: XXXXX XXXXX (16 ft. lbs.).16. Tighten the intake manifold steady bar bolts, beginning with the one in the cylinder block, and plug in the temperature sensor connector.17. Install the bolts securing the water pipe to the thermostat housing cover and connect the throttle body preheating hose.18. Install the lifting eyes and the bracket for the electrical connections.19. Connect the crankcase breather and vacuum hoses and install the dipstick tube and bracket.20. Plug in the ignition discharge module connector.21. Connect the coolant hoses to the cylinder head.22. Install the nuts for the front exhaust pipe, tighten to: XXXXX XXXXX (16 ft. lbs.).23. This step is not applicable to this model.24. Install the servo pump and install the pulley back in place.• Install the belt and check the position of all pulleys.25. Relieve the belt tensioner of strain, using a ratchet handle extension, and remove the drill.26. This step is not applicable to this model.27. This step is not applicable to this model.28. Install the air cleaner.• Install the inlet hose back in place and connect the mass air flow sensor.29. Connect the negative battery cable, check that the radiator drain plug is tight, top up with coolant and check the system for leaks.30. Check the coolant and engine oil levels and top up as necessary.31. Install the cover or resonator, remove the protective sheets over the fenders and check that the engine bay is clean.32. Start the engine and check all functions.• Take the car out on a road test.

And here are the pictures to reference for installation:

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This are the sections, you can go through and click the link to read its troubleshooting.